Apparatus and methods for handling rotor blades

ABSTRACT

An apparatus for handling rotor blades of wind power installations. An apparatus for simplified handling of rotor blades is afforded by a carrier element and at least one rotor blade receiving means fixedly connected thereto. A rotor blade is received in the apparatus during a blade fitting procedure. The apparatus may reduce the effect of the wind and the effect of mass inertia during the blade fitting procedure.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.10/517,133, filed Jun. 29, 2005, now pending.

BACKGROUND

1. Field

This disclosure concerns an apparatus for handling rotor blades of windpower installations.

2. Description of the Related Art

For the assembly of wind power installations inter alia the rotor huband the rotor blades are generally transported to the building siteindividually, because of their considerable dimensions. At the site theyare then assembled to form a rotor unit.

Various assembly procedures are considered for that purpose. In oneprocedure the rotor blades are mounted to the rotor hub on the groundand the entire rotor unit is then conveyed into the assembly positionand fitted there, by a crane.

In another procedure the rotor hub is firstly mounted to the head of thewind power installation. Thereafter the rotor blades are liftedindividually to the rotor hub and there assembled in situ.

In both cases however it is necessary to handle the large rotor bladesweighing several tons, move them precisely into the respectiveinstallation situation and hold them there.

That is implemented by a crane which lifts the rotor blade with straps(or chains), moves it into its installation situation and holds itthere. For that purpose the straps are laid around the rotor blade atpredetermined positions. The rotor blade is then lifted and transported.

BRIEF SUMMARY

In one aspect, an embodiment provides an apparatus for the simplifiedhandling of a rotor blade.

In another aspect, an embodiment comprises a rigid carrier element withat least one rotor blade receiving means fixedly connected thereto.

In that respect, the effect of wind during the blade-fitting procedureon the one hand and the effect of mass inertia on the other hand arereduced.

In another embodiment, a ball rotary joint arranged on the carrierelement permits a rotary movement of the apparatus with the rotor bladein a defined rotary plane. In order to facilitate such a rotary movementby machine, a rotary mechanism drive can be provided at the ball rotaryjoint.

In another embodiment, eyes can be provided at mutual spacings forvarious tasks, such as for example fixing securing cables and/or guidecables. Guide cables make it possible to provide manually for examplefor orientation of the rotor blade in the event of failure of or inplace of the rotary mechanism drive, from the ground.

In order to provide a particularly simple receiving configuration forthe rotor blades, the rotor blade receiving means in one embodiment canbe in the form of a frame which encloses the rotor blade at least threesides.

In another embodiment, a locking member is mounted pivotably at one sideof the rotor blade receiving means. That locking member permits therotor blade receiving means to be closed at the fourth side so that therotor blade is reliably prevented from unintentionally sliding out ofthe rotor blade receiving means.

In another embodiment, the rotor blade is held securely in the rotorblade receiving means, in one embodiment the rotor blade receiving meansembraces the rotor blade in positively locking relationship.

In another embodiment the rotor blade receiving means is of such aconfiguration that cushions are provided between the rotor bladereceiving means and the rotor blade in order to avoid damage to therotor blade.

In one embodiment those cushions are inflatable. In that way the rotorblade can be accommodated in the rotor blade receiving means when thecushions are initially uninflated. As soon as the rotor blade is in thepredetermined position the cushions are inflated with a predeterminablepressure. In that way on the one hand the rotor blade is fixed in thedesired position while on the other hand damage to the rotor blade isprevented.

In order to facilitate transport of a rotor blade with the apparatusaccording to one embodiment, the apparatus is of such a furtherconfiguration that there are provided valves for filling and/or emptyingthe inflatable cushions. There may also be provided an energy storagemeans and/or a pressure storage means and/or at least one plug connectorfor the connection of an electric and/or hydraulic and/or pneumaticline. That configuration of the apparatus according to one embodimentmeans that the inflatable cushions as well as the energy storage meansand the pressure storage means can be filled. They can then be separatedfrom the lines and permit the apparatus to be transported with the rotorblade, in which case any pressure losses which may occur in the cushionscan be compensated by the storage means. The energy storage means, forexample a capacitor of suitable size or a chemical storage means such asan accumulator provide in that situation the required energy for acontrol system and for the actuation of suitable control devices such asvalves. It will be appreciated that in that respect suitable sensors mayalso be included.

In an alternative embodiment of the invention the apparatus includes atleast one carrier bar and a carrier plate, wherein the carrier barengages through a through opening provided in the rotor blade and endsat the carrier plate. That arrangement provides that the carrier plateforms the contact surface for the rotor blade and can be of a suitablylarge dimension and suitably cushioned. The carrier bar extends throughthe rotor blade and thus makes a fixed connection between the carrierdevice and the rotor blade.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Embodiments of the invention are described in greater detail hereinafterwith reference to the figures in which:

FIG. 1 shows a front, left, isometric view of an apparatus for handlinga rotor blade according to a first illustrated embodiment of theinvention,

FIG. 2 shows a cross-sectional view of the apparatus of FIG. 1,

FIG. 3 shows a front, left, isometric view of an apparatus for handlinga rotor blade according to a second illustrated embodiment of theinvention,

FIG. 4 shows a cross-sectional view of an apparatus for handling a rotorblade having a carrier bar according to another illustrated embodimentof the invention, and

FIG. 5 shows a cross-sectional view of an apparatus for handling a rotorblade having a rotatable carrier bar according to yet anotherillustrated embodiment of the invention.

DETAILED DESCRIPTION

A carrier element 10 is provided in FIG. 1. That carrier element 10 asillustrated is of a rectangular shape. Provided at the center of thatcarrier element 10 is a ball rotary joint 12. Even when the apparatus issuspended rigidly, for example by being bolted to the roller head of acrane, that ball rotary joint permits a rotary movement of the entireapparatus about the vertical axis.

Provided opposite the carrier element 10 is a bottom element 16. Thebottom element 16 is of substantially the same dimensions and shape asthe carrier element 10. A side element 14 is provided between thecarrier element 10 and the bottom element 16. Eyes 26 are shown on thatside element 14. Cables can be passed through the eyes 26, which forexample permit the entire apparatus to be rotated about its verticalaxis, even when it has already been lifted by a crane.

The arrangement of the carrier element 10, the bottom element 16 and theside element 14 affords an open apparatus 1 which receives the rotorblade. So that the apparatus 1 encloses the rotor blade at four sides,there can be a further side element 18. That second side element 18 ishowever mounted pivotably by a hinge 22 to the carrier element 10.Therefore, the pivotal movement of that second side element 18 can openan opening through which the rotor blade can be received by or releasedfrom the apparatus 1.

So-called container corners 20 are also shown at predetermined positionsof the carrier element 10 and the bottom element 16. Those containercorners 20 permit the apparatus 1 to be connected on the one hand tofurther apparatuses of the same configuration and also for exampleduring transport of a rotor blade to the transport vehicle, in a simplemanner.

Just as for actuation of the second side element 18, a respectivesuitable rotary drive mechanism 13 can also be provided for actuation ofthe ball rotary joint 12. It will be appreciated that, in the case ofthe ball rotary joint 12, that can be a drive motor while for exampleelectrical, hydraulic or pneumatic devices can be used for actuation ofthe second side element 18.

FIG. 2 shows a side view of an apparatus 1 according to an embodiment ofthe invention with a rotor blade 29. Provided in this Figure within theapparatus according to the invention which is formed by the carrierelement 10, the bottom plate 16, the first side wall 14 and the secondside wall 18 which is mounted pivotably to the carrier element 10, arecushions 24 which on the one hand securely hold the rotor blade 29 inits predetermined position and on the other hand protect it from damageby the apparatus.

Those cushions 24 can be inflatable (with gas or liquid). In that way itis possible without any problem for the rotor blade 29 to be received byor released from the apparatus 1 and the rotor blade 29 can nonethelessbe held in a simple fashion. In that respect the cushions 24 can beinflated to a first pressure at which the rotor blade 29 can be held ina substantially secure manner without causing damage to the rotor blade29.

FIG. 3 shows an alternative embodiment of the apparatus 1 according tothe invention. In this embodiment, the carrier element 10 can be smallerbut it again has a ball rotary joint 12. It will be appreciated that asuitable drive can be provided at the ball rotary joint 12.

Longitudinal bearers 28 are arranged at two opposite sides of thecarrier element 10. Mounted to those longitudinal bearers 28 once againat two opposite sides of the carrier element 10 is a rotor bladereceiving means 17 comprising upper elements 11, side elements 14 andbottom elements 16. Here the rotor blade receiving means 17 is shown asbeing open at one side. It will be appreciated that it is also possibleto provide there a pivotably mounted element which permits the rotorblade receiving means 17 to be closed at the open side so that a rotorblade (see rotor blade 29 of FIG. 2) accommodated therein is againenclosed at all four sides. For the sake of clarity, also the containercorners (see reference 20 in FIG. 1) and the eyes (see reference 26 inFIG. 1) are not shown in the illustrated embodiment. One skilled in theart will appreciate and understand that features described in oneembodiment may be included in other embodiments.

This alternative embodiment of the apparatus according to the inventioncan weigh less and yet still have adequate strength.

FIG. 4 shows a further embodiment of an apparatus 1 according to theinvention. This apparatus can be used to particular advantage inrelation to rotor blades which have a through hole between the top sideand the underside (that is to say the reduced-pressure side and theincreased-pressure side in the case of rotor blades which act on thebasis of the lift principle). In this embodiment the ball rotary joint12 is again provided on the carrier element 10. Adjoining the carrierelement 10 is a carrier bar 30 which is fixedly connected to the carrierelement 10. A carrier plate 32 is provided at the end of the carrier bar30, which is in opposite relationship to the carrier element 10. Thecarrier plate 32 is secured releasably to the carrier bar 30; thecarrier bar 30 can therefore be passed through the through hole in therotor blade, after removal of the carrier plate 32. Subsequently thecarrier plate 32 is fixed to the end of the carrier bar 30 and thusclamps the rotor blade (not shown) in position.

As the carrier bar 30 can be passed in a particularly simple fashionthrough the through hole in the rotor blade (not shown) when a clearancefit is involved, but such clearance is unwanted during the transportoperation, it is possible to provide on the carrier bar a variableportion 34, such as for example an inflatable bellows, which fills upthe intermediate space between the carrier bar 30 and the rotor blade(not shown) and thus substantially eliminates relative movement betweenthe carrier bar 30 and the rotor blade.

FIG. 5 shows a further embodiment of an apparatus 1 according to theinvention. That apparatus 1 again has a carrier element 10 with a ballrotary joint 12. In addition a carrier bar 30 is once again mounted tothe carrier element 10 while the carrier plate 32 is again disposed atthe opposite end thereof. It will be noted that, in this embodiment, thecarrier bar 30 is connected to the carrier element 10 rotatably aboutthe longitudinal axis of the carrier bar 30. In a central portion thecarrier bar 30 also has a locking member 36.

One skilled in the art will appreciate and understand that there can bemany different possible options in regard to the configuration of thelocking member 36. For example, one option is a fixed locking memberwhich, after insertion into the rotor blade, is rotated together withthe carrier bar 30 so that it engages into a corresponding openingprovided within the rotor blade, and thus forms a releasable but firmconnection to the rotor blade.

It will be appreciated that alternatively it is also possible to providemovable elements which are moved in situ into a locking position inorder to form the connection between the rotor blade and the apparatus.

The various embodiments described above can be combined to providefurther embodiments. All of the U.S. patents, U.S. patent applicationpublications, U.S. patent applications, foreign patents, foreign patentapplications and non-patent publications referred to in thisspecification and/or listed in the Application Data Sheet, areincorporated herein by reference, in their entirety. Aspects of theembodiments can be modified, if necessary to employ concepts of thevarious patents, applications and publications to provide yet furtherembodiments.

These and other changes can be made to the embodiments in light of theabove-detailed description. In general, in the following claims, theterms used should not be construed to limit the claims to the specificembodiments disclosed in the specification and the claims, but should beconstrued to include all possible embodiments along with the full scopeof equivalents to which such claims are entitled. Accordingly, theclaims are not limited by the disclosure.

1. An apparatus for handling rotor blades of wind power installations,the apparatus comprising: a carrier element; means for receiving atleast one rotor blade, the rotor blade receiving means being connectedto the carrier element and including a carrier frame configured toenclose at least one rotor blade about at least three sides uponhandling and to allow maneuvering the rotor blade toward the wind powerinstallation, to reduce an effect of wind on the rotor blade when the atleast one rotor blade is installed on the wind power installation; and aball rotary joint arranged on the carrier element.
 2. The apparatusaccording to claim 1, further comprising: a rotary mechanism drive atthe ball rotary joint.
 3. The apparatus according to claim 1, furthercomprising: a plurality of eyes mutually spaced in a longitudinaldirection of the carrier element for receiving cables.
 4. The apparatusaccording to claim 1 wherein the carrier frame is configured to enclosethe at least one rotor blade about four sides upon handling.
 5. Theapparatus according to claim 1, further comprising: a locking memberpivotably coupled to one side of the rotor blade receiving means.
 6. Theapparatus according to claim 1 wherein the rotor blade receiving meansis configured to engage the at least one rotor blade in a complementarylocking relationship.
 7. The apparatus according to claim 1, furthercomprising: a plurality of cushions provided throughout the rotor bladereceiving means.
 8. The apparatus according to claim 7 wherein thecushions are inflatable.
 9. The apparatus according to claim 7 whereinthe cushions include valves for inflating/deflating the cushions. 10.The apparatus according to claim 1, further comprising: at least one ofmeans for storing energy, means for storing pressure, and a plugconnector to connect at least one of an electrical line, a hydraulicline, and a pneumatic line, wherein the energy storage means, pressurestorage means, or plug connector is used to maintain a first pressure ina plurality of cushions located in the rotor blade receiving means. 11.The apparatus according to claim 1 wherein the rotor blade receivingmeans includes at least one carrier bar extending perpendicularly withrespect to the carrier element facilitating retention of the rotorblade.
 12. The apparatus according to claim 11 wherein the carrier baris configured to extend through a through hole of the rotor blade. 13.The apparatus according to claim 11, further comprising: a carrier platereleasably fixed to the at least one carrier bar further facilitatingretention of the rotor blade.
 14. The apparatus according to claim 11wherein a cross-section of the carrier bar is variable over at least oneregion.
 15. The apparatus according to claim 1, further comprising: adevice for bolting the apparatus to a roller head of a crane.
 16. Theapparatus according to claim 1, further comprising: a plurality ofcontainer corners positioned on at least one of either a top side and anunderside of the apparatus.
 17. The apparatus according to claim 1wherein the carrier element is rigid.
 18. A method for securing andhandling at least one rotor blade, the method comprising: placing the atleast one rotor blade into a carrier element that is configured toreduce an effect of the wind on the at least one rotor blade, thecarrier element surrounding the at least one rotor blade on at leastthree sides; protecting the at least one rotor blade against damageassociated with a contact of the at least one rotor blade with thecarrier element; and maneuvering the carrier element toward a wind powerinstallation.
 19. The method of claim 18, further comprising: handlingthe carrier element and the at least one rotor blade via a ball rotaryjoint mounted on the carrier element.
 20. The method of claim 18,further comprising: opening the carrier element to release the at leastone rotor blade.
 21. The method of claim 18 wherein protecting the atleast one rotor blade includes inflating cushions located in the carrierelement and substantially around the at least one rotor blade.
 22. Anapparatus comprising: receiving means for receiving at least one rotorblade, the receiving means configured to reduce an effect of wind on theat least one rotor blade when the at least one rotor blade is installedon a wind power installation; and attachment means for maneuvering thereceiving means comprising a ball rotary joint arranged on the carrierelement to allow maneuvering the rotor blade receiving means, with therotor blade received therein, toward the wind power installation, toreduce an effect of wind on the rotor blade when the at least one rotorblade is installed on the wind power installation.
 23. An apparatus forhandling rotor blades of wind power installations, the apparatuscomprising: a carrier element; means for receiving at least one rotorblade connected to the carrier element, the rotor blade receiving meansincluding a carrier frame configured to enclose at least one rotor bladeabout at least three sides upon handling and at least one carrier barextending perpendicularly with respect to the carrier element andconfigured to extend through the rotor blade when the rotor blade isreceived in the rotor blade receiving means.